BPW TS2 4309 Caliper Assembly: Correct Lever Alignment, Mechanism Setup & Tips

⁣In this video we assemble the BPW TS2 4309 brake caliper from start to finish and eliminate common mistakes: surface prep, forged lever selection, mechanism orientation, pin–bearing flat alignment, greasing points, spring and cap placement, Loctite use, brake chamber connection, and pad spring/retainer installation.


Follow these steps to prevent sticking, off-center force, disc rubbing, and premature wear.


⁣Key steps & checkpoints

Cleaning: Ensure the caliper body and guide bores are thoroughly clean before assembly.

Lever (forged): Use the forged lever; the bearing track surface must be undamaged.

Mechanism orientation: Mechanism and lever must face the lever side when installed.

Pin–bearing alignment: The flat on the bearing must mate with the lever’s flat; the pin must seat fully in the lever pocket.

Greasing: Apply sufficient but controlled grease on the lever, pin, and contact faces; a light sealing ring of grease helps stabilize motion.

Springs & cap: Fit the two springs in the correct direction, then install the cap; always use the cap seal to keep out water/dust.

Fasteners: On BPW units, apply Loctite to bolts per spec.

Brake chamber:

An overly long or off-center pushrod can preload the mechanism, causing pad drag.

Keep the linkage centered and straight; avoid low-quality chambers that fail early.


Function test: Lever should travel freely to end positions without rubbing or binding.

Pad spring/retainer: Incorrect orientation shifts the pad and causes noise/drag.

Sensitivity: TS2 4309 is tolerance-sensitive; proceed slowly and methodically.

Frequent mistakes

Forcing the pin without matching the lever/bearing flats

Mounting the mechanism facing away from the lever side

Over/under-greasing or greasing the wrong locations

Skipping the cap seal

Off-center or excessive brake-chamber pushrod length

Reversing or omitting the pad spring/retainer


⁣Who is this for?

Heavy-duty service shops, fleet maintenance, caliper rebuilders, and technicians working on BPW TS2 4309 calipers.